Modular building system

ABSTRACT

A modular building system that has three main components: a selection of tube sections, a selection of removable connectors that can connect multiple tube sections together at various angles to form a structural skeleton having geometrically shaped sides, and a selection of geometrically shaped structural panels that structurally engage the geometrically shaped side panels of the structural skeleton is disclosed. The removable connectors may be removed after the panel sections are installed. The panel sections can provide additional structural support and strength to the structural skeleton with the inclusion of additional bracing and supports. The panel sections can also have a pre-finished surface. The panel sections may also have additional features to facilitate construction, such as providing for insulation, the routing of electrical wiring, plumbing lines, ventilation ductwork, or communications cabling.

FIELD OF THE INVENTION

The present invention relates to building systems, and more specifically to a modular building system.

BACKGROUND OF THE INVENTION

A simple and versatile building system has been sought for generations. From the first attempts to construct their own shelters, mankind has continually looked for innovative ways to build. There are many building systems in use today. Each system has its own advantages and disadvantages based on cost, complexity, ease of construction, weight, strength, versatility, and durability. In an attempt to reduce cost and improve versatility by standardizing many components, modular building systems are one approach to construction.

A modular construction system is disclosed in U.S. patent application Ser. No. 09/834,624, by Pries, which was published by the U.S.P.T.O., on Sep. 13, 2001 as Publication No. US2001/0020352. The Pries system uses a set of panels and shapes derived from the sides of a cube divided into twenty-seven (27) sub-cubes. The panels are connected to struts that are part of the panels or independent members. The panels and struts are connected via integral joinery assemblies that are part of the ends of the struts and sides of the panels. The joinery assemblies are similar to hinges and use brackets to securely fasten the various pieces together.

U.S. patent application Ser. No. 09/726,237, by Pryor et al., which was published by the U.S.P.T.O. on May 30, 2002, as Publication No. US2002/0062611, discloses a cellular-core structural panel and a building structure incorporation the cellular-core structural panel. The panel incorporates a honeycomb or other cellular core sandwiched between two metal face sheets and surrounded by a metal frame. The frame sides define interlocking protrusions and channels that interlocking joints between panels. Brackets are used to attach the panels to other parts of the structure.

U.S. Pat. No. 6,332,298, issued to Bigelow, discloses a portable building construction system. The building system uses a series of beams, headers, tubular supports, and blocks to create a building frame. Walls, floors, and a roof can then be attached to the frame.

U.S. Pat. No. 6,295,778, issued to Burt, discloses modular building structures comprised of extruded components. In the Burt invention, wall sections are constructed from extruded components that stack together and may be connected by fastening panels.

U.S. Pat. No. 6,178,714, issued to Carney, Jr., discloses a modular temporary building. The building has a poured concrete foundation, having regularly spaced holes for vertical block assembly rods. Wall blocks, having corresponding holes are placed on the foundation. The rods are run through the holes in the blocks down to the holes in the foundation. The invention further discloses a roof system for the building having the walls described above.

U.S. Pat. No. 6,179,211, issued to Boyce, discloses a demountable wall system. The wall system is designed to be mounted between, but not attached to the floor and ceiling of a building having a plurality of wall sections. The wall system uses upper and lower horizontal members that mount or interface with the floor and ceiling of the building. Between the horizontal members, there are mounted vertical panels and vertical frame members, as well as frame members for mounting a door.

U.S. Pat. No. 6,082,066, issued to Mill, discloses another modular building system. The Mill system uses an integrated construction panel that has a grid of structural studs. A rigid frame surrounds the grid, where the frame is designed to mate to the frame of an adjacent panel. Each panel has front and rear surfaces that are attached to the frame. The surfaces create and substantially enclosed space, which is substantially filled with closed cell foam.

U.S. Pat. No. 5,371,985, issued to Suttles, discloses a modular building structure for converting an existing building interior to a convenience store. The modular structure is made up of a grid of metal tubes positioned on the floor of the existing building and metal floor panels that are supported on the grid. Upright wall supports are provided at intervals around the periphery of the floor structure. Sheet metal-framed wall, window, and door modules are removably connected between the upright supports. The upright supports also have shelf-supporting slots, which permit shelving to be mounted on the walls.

International Patent Application PCT/AU90/00527, which was published on May 16, 1991, as International Publication Number WO 91/06725, discloses another modular building system. This modular system includes wall panels joined to one another by interleaving a plurality of coaxial tubes aligned along the edges of the panels.

U.S. Pat. No. 4,884,376, issued to DeBlock, et al., discloses a modular sun porch. The porch has wall assemblies made from modular window panels whose lateral edges interfit in male/female relationship to provide weather seals therebetween. Modular door units can be substituted for window panels. The invention also includes a roof having rafters and purlins which slide-lock into position between beams and rafters, respectively. Roof panels rest on gaskets carried by the rafters and purlins. Retainers are secured to the rafters to retain the panels in position and to improve the weather seal.

U.S. Pat. Nos. 4,583,333 and 4,571,899, issued to Minter, disclose a type of construction for room additions. An upright frame assembly is mounted on a foundation. Structurally independent panel members are securely mounted in each of the frame portions. The panel members cooperate with the frame assembly for providing load bearing support to the structure.

U.S. Pat. No. 3,987,597, issued to Smrt, discloses a modular structural assembly and method of construction. The modular structural assembly is formed from a frame assembly and a plurality of rectangular panels which are releasably secured to the frame. Each panel is formed from four struts which are interconnected and a sheet which is stretched over the struts and secured thereto. Each strut includes and outwardly extending flange which is secured to the frame by clips mounted on the frame.

U.S. Pat. No. 3,759,001, issued to Judkins et al., discloses another demountable wall construction. The modular system uses widely spaced vertical studs with a wall panel extending between the studs and slightly overlapping them. Panel holders secure the panels to the studs. The studs are interconnected by upper and lower horizontal members.

U.S. Pat. No. 3,623,290, issued to Dowling, Jr., discloses a partition wall. The movable partition wall employs panels which are detachably mounted on studs. The panels have parallel marginal edges along which are disposed continuous tongues with coextensive stops. The studs are provided with spaced fingers extending toward the panels. Each finger is substantially coextensive with the stud and carries a continuous shoulder for interlocking engagement with a stop when the tongues for the panels are inserted between the fingers of the studs.

While each invention discussed above is meritorious in its own right, there is a need to develop a more versatile, structurally sound, modular building system. Particularly there is need to develop a modular building system that is easy assemble and disassemble and wherein wall, ceiling, roof and floor panels add to the structure of the system and are not merely attachments to a frame. There is a need to have panels that can have a pre-finished surface. Additionally, there is a need to have panels that can provide a mechanism for routing insulation, electrical wiring, plumbing lines, ventilation ducts, and communications cabling within the panels.

SUMMARY

In view of the insufficiencies discussed above, it is an object of the present invention to provide a modular building system. It is a further object of the present invention to provide a modular building system, wherein panel sections, once installed in structural skeleton become part of the building structure, thus allowing the removal, and eventual reuse, of connectors that are used to connect members of the skeleton during construction. It is a further object of the present invention to provide a modular building system that has panel section that have a pre-finished surface. It is a further object of the present invention to provide a modular building system that provides for the routing of electrical wiring, plumbing lines, ventilation ducts, and communications cabling within the panels. It is a further object of the present invention to provide a method of construction using a modular building system.

The present invention is a modular building system that has three main components: a selection of tube sections, a selection of removable connectors that connect the tube sections together to form a structural skeleton having geometrically shaped sides, and a selection of geometrically shaped structural panels that structurally engage the geometrically shaped side panels of the structural skeleton.

The tube sections can have a variety of configurations. The tube sections can have an open or closed cross section and can be made of metal or other materials suitable for building a structure. In various embodiments the tube sections can have additional features to help facilitate construction. The additional features may include one or more channels to receive a flange on either the removable connectors or the panel sections, or holes disposed around the periphery and along the length of the tube sections.

The removable connectors are configured to hold multiple tube sections together at various angles to form a three dimensional structural skeleton for the structure being built. The structural skeleton then has various geometrically shaped sides onto which the geometrically shaped panel sections are attached. Once the panel sections are attached, the removable connectors can be removed without affecting the structural integrity of the structure. The removable connectors can have either an open cross section or a closed cross section construction and can have one or more flanges for engaging channels on the tube sections. Additionally, the removable connectors can have holes, corresponding to the holes in the tube sections, for receiving a fastener.

The geometrically shaped panel sections structurally attach to corresponding geometrically shaped sides of the structural skeleton. The panel sections can have one or more flanges for engaging channels on the tube sections. Additionally, the panel sections can have holes, corresponding to the holes on the tube sections, for receiving a fastener. The panel sections can provide additional structural support and strength to the structural skeleton with the inclusion of additional bracing and supports. The panel sections can also have a pre-finished surface. The panel sections may also have additional features to facilitate construction, such as providing for insulation, the routing of electrical wiring, plumbing lines, ventilation ductwork, or communications cabling.

Other features and advantages of the invention will be apparent from the following detailed description take in conjunction with the following drawings, wherein like reference numeral represent like features.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A illustrates an expanded view of a simple structure built according to the present invention.

FIG. 1B illustrates a structural skeletal of a simple structure built according to the present invention.

FIG. 1C illustrates structural panels attached to a structural skeleton of a simple structure built according to the present invention.

FIG. 1D illustrates an assembled simple structure built according to the present invention, with removable connectors removed.

FIG. 2A illustrates a second simple structure built according to the present invention.

FIG. 2B illustrates a removable connector of the present invention.

FIG. 2C illustrates a second removable connector of the present invention.

FIG. 3A illustrates a square shaped structural panel of the present invention.

FIG. 3B illustrates a triangle shaped structural panel of the present invention.

FIG. 4 illustrates another simple structure built according to the present invention.

DETAILED DESCRIPTION OF THE INVENTION

While this invention is susceptible of embodiments in many different forms, there are shown in the drawings, and will herein be described in detail, preferred embodiments of the invention with the understanding that the present disclosure is to be considered as an exemplification of the principles of the invention and is not intended to limit the broad aspect of the invention to the embodiments illustrated.

The present invention is a modular building system having a selection of tube sections 100, a selection of removable connectors 110, and a selection of panel sections 120. The removable connectors 110 are used to connect the tube section 100 together to form a structural skeleton 130. The structural skeleton 130 can have a variety of geometrically shaped sides 140. The panel sections 120 structurally attach to the structural skeleton 130 formed from the tube sections 100 and the removable connectors 110. In various embodiments, the removable connectors 110 can be removed after the panels sections 120 are attached to the tube sections 100.

FIG. 1A illustrates an expanded view of a simple structure built according to the present invention. In FIG. 1B, the tube sections 100 are joined together by the removable connectors 110 to form the structural skeleton 130. In FIG. 1C, the panel sections 120 are attached to the structural skeleton 130. FIG. 1D shows the completed simple structure, wherein the removable connectors 110 have been removed.

The tube sections 100 can have a variety of configurations. The tube sections 100 can have an open or closed cross section. Examples of open cross section tubes include, but are not limited to, I-beam, U-channel, T-section, and angle sections. Example of closed sections tubes include square, round (circular), and semicircular tube sections. Other closed polygon sections, such as, triangle, rectangle, pentagon, hexagon, octagon, and trapezoid tube sections may be used as well. The tube sections 100 can be made of metal or other materials suitable for building a structure.

In various embodiments of the present invention, the tube sections 100 can have additional features. The tube sections 100 may have one or more channels, not shown, to receive a flange, not shown, on either the removable connectors 110 or the panel sections 120. To help facilitate construction, the tube sections 100 can have holes 150 disposed around their periphery and along their length. The holes 150 can be spaced in any desired arrangement, including being evenly or unevenly distributed along the length of the tube section 100. The holes 150 can be configured to receive a fastener (not shown), including, but not limited to, a bolt, rivet, or screw. The tube sections 100 and holes 150 therein may also serve as conduits or passages for electrical wiring, plumbing lines, ventilation ductwork, and communication cabling.

FIG. 2A illustrates a second simple structure built according to the present invention. FIG. 2B is a close up view of a first removable connector 110 in accordance with the present invention. FIG. 2C is a close up view of a second removable connector 110.

The removable connectors 110 are configured to hold the tube sections 100 together to form a three dimensional structural skeleton 130 for the structure being built. The removable connectors 110 can hold multiple tube sections 100 at various angles to form the skeleton 130. The structural skeleton 130 then has various geometrically shaped sides 140, such as squares, rectangles, triangles, circles, and semicircles as well as other geometric and polygonal shapes, onto which the geometrically shaped panel sections 120 are attached. Once the panel sections 120 are attached to the tube sections 100, the removable connectors 110 can be removed without affecting the structural integrity of the structure.

The removable connectors 110 can have either an open cross section or a closed cross section construction and be made from of materials suitable for building. To help facilitate construction, the removable connectors 110 can have one or more flanges, not shown, for engaging channels, not shown, on the tube sections 100. The removable connectors 110 can also have holes 160, corresponding to the holes 150 in the tube sections 100, for receiving a fastener, not shown.

The geometrically shaped panel sections 120 structurally attach to corresponding geometrically shaped sides 140 of the structural skeleton 130. Panel sections 120 may attach to either the interior other the exterior of the structural skeleton 130, or both the interior and the exterior of the structural skeleton. FIG. 4 illustrates a simple structure built according to the present invention, where the structure has interior and exterior panel sections 120. The panel sections 120 can have one or more flanges, not shown, for engaging channels, not shown, on the tube sections 100. Alternately, flanges on the panel sections 120 could engage the tube sections 100 without engaging a channel on the tube sections 100. For example, in a structural skeleton 130 wherein the tube sections 100 are square, the flanges depth can be one-half the size of a side of the tube section 100, conversely, each side of the tube section 100 is twice the size of the flange depth on the panel sections 120. This allows two panel sections 120, an interior panel and an exterior panel to be attached to each tube section 100. In yet another alternative, flanges on the panel sections 120 could engage other panel sections 120, either through engaging a corresponding channel, flange, or other portion of the panel section 120. Additionally, the panel sections 120 can have holes 170, corresponding to the holes 150 on the tube sections 100, for receiving a fastener, not shown.

The panel sections 120 can provide additional structural support and strength to the structural skeleton 130 with the inclusion of additional bracing and supports, such as angle bracing, cross bracing, horizontal support members, and/or vertical support members, and/or expandable structural foam. FIGS. 3A and 3B illustrate panel sections 120 according to the present invention. The triangular sections are ideally raised areas of the panel 120, which may have recessed interiors which recess back to the surface of the panel 120, having channels 180 therebetween and formed about their perimeters. The recessed interiors of the triangular sections can thus provide clearance for fasteners to be applied through the perimeter sections into the tubes 100. Channels 180 thus form recessed areas, relative to the triangular perimeter sections, where tubes 100 are disposed or attached. In certain embodiments, channels 180 are approximately half the depth of tubes 100, such that interior and exterior panels 120 can sandwich tubes 100. Channels 180 generally intersect at recessed polygonal areas, such as the octagonal areas shown in FIG. 3A.

The panel sections 120 can also have a pre-finished surface, not shown. The pre-finished surface can be an interior or exterior surface. Examples of a pre-finished exterior surface can include, but are not limited to, siding, shingles, brick, ceramic glass, ceramic tiles, metal-roofing systems, composites, metal sheets, stones, crushed stones, rubber, wood, hydrocarbon derivates exterior construction finishes, natural fibres, and synthetic fibres. Pre-finished interior surfaces can include, but are not limited to, flooring, sub-flooring, drywall, ceramics, glass, metal sheets, stones, crushed stones, rubber, hydrocarbon derivates interior construction finishes, composites, wood, natural fibres, and synthetic fibres. It should be apparent that other exterior and interior surfaces may also be used.

The panel sections 120 may also have additional features to facilitate construction. For example, the panel sections 120 may provide for the routing of electrical wiring, plumbing lines, or ventilation ductwork. Likewise, the panel sections 120 may provide for the routing of communication cabling, such as cable television cables, telephone wiring, or other similar utilities or services that are routed through walls. Additionally, the panel sections 120 may provide for the mounting of different types of weather insulating materials.

The present invention also includes the process of building a structure out of the modular building system described above. The process includes the steps of connecting a selection of tube sections 100 together using a selection of removable connectors 110. The tube sections 100 and the removable connectors 110 form a structural skeleton 130 having geometrically shaped sides 140. Next, a selection of geometrically shaped structural panels 120 is attached to the corresponding geometrically shaped sides 140 of the structural skeleton 130. Optionally, the removable connectors 110 can be removed after connecting the structural panels 120.

While specific embodiments have been illustrated and described, numerous modifications come to mind without significantly departing from the spirit of the invention, and the scope of protection is only limited by the scope of the accompanying claims. 

1. A modular building system, comprising: a selection of tube sections, a selection of removable connectors, wherein said connectors connect said tube sections together to form a structural skeleton comprising geometrically shaped sides, and a selection of geometrically shaped panel sections wherein said panel sections structurally engage said geometrically shaped sides of said structural skeleton.
 2. The modular building system according to claim 1, wherein said tube sections have a closed cross section.
 3. The modular building system according to claim 1, wherein said tube sections have an open cross section.
 4. The modular building system according to claim 1, wherein said tube sections comprise square tubing.
 5. The modular building system according to claim 1, wherein said tube sections comprise round tubing.
 6. The modular building system according to claim 1, wherein said tube sections comprise at least one channel to receive a flange on said connectors.
 7. The modular building system according to claim 1, wherein said tube sections comprise a channel to receive a flange on said panel sections.
 8. The modular building system according to claim 1, wherein said tube sections comprise a plurality of holes for receiving a fastener.
 9. The modular building system according to claim 8, wherein said holes are distributed along the length of said tube sections.
 10. The modular building system according to claim 8, wherein said holes are evenly spaced along the length of said tube sections.
 11. The modular building system according to claim 8, wherein said holes are unevenly spaced along the length of said tube sections.
 12. The modular building system according to claim 8, wherein said fasteners comprise bolts.
 13. The modular building system according to claim 8, wherein said fasteners comprise rivets.
 14. The modular building system according to claim 8, wherein said fasteners comprise screws.
 15. The modular building system according to claim 1, wherein said removable connectors have a closed cross section.
 16. The modular building system according to claim 1, wherein said removable connectors have an open cross section.
 17. The modular building system according to claim 1, wherein said removable connectors comprise square tubing.
 18. The modular building system according to claim 1, wherein said removable connectors comprise round tubing.
 19. The modular building system according to claim 1, wherein said removable connectors comprise at least one flange for engaging a channel on said tube sections.
 20. The modular building system according to claim 1, wherein said removable connectors comprise a plurality of holes for receiving a fastener.
 21. The modular building system according to claim 20, wherein said holes are distributed along the length of said removable connectors.
 22. The modular building system according to claim 20, wherein said holes are evenly spaced along the length of said removable connectors.
 23. The modular building system according to claim 20, wherein said holes are unevenly spaced along the length of said removable connectors.
 24. The modular building system according to claim 1, wherein said panel sections comprise at least one flange for engaging said tube sections.
 25. The modular building system according to claim 1, wherein said panel sections comprise a plurality of holes for receiving a fastener.
 26. The modular building system according to claim 1, wherein said panel sections comprise square panels.
 27. The modular building system according to claim 1, wherein said panel sections comprise triangular panels.
 28. The modular building system according to claim 1, wherein said panel sections comprise rectangular panels.
 29. The modular building system according to claim 1, wherein said panel sections comprise circular panels.
 30. The modular building system according to claim 1, wherein said panel sections comprise semicircular shaped panels.
 31. The modular building system according to claim 1, wherein said panel sections comprise polygonal shaped panels.
 32. The modular building system according to claim 1, wherein said panel sections comprise at least one pre-finished surface.
 33. The modular building system according to claim 32, wherein said at least one pre-finished surface comprises a pre-finished exterior surface.
 34. The modular building system according to claim 33, wherein said pre-finished exterior surface comprises siding.
 35. The modular building system according to claim 33, wherein said pre-finished exterior surface comprises shingles.
 36. The modular building system according to claim 33, wherein said pre-finished exterior surface comprises bricks.
 37. The modular building system according to claim 32, wherein said at least one pre-finished surface comprises a pre-finished interior surface.
 38. The modular building system according to claim 37, wherein said pre-finished interior surface comprises sub-flooring.
 39. The modular building system according to claim 37, wherein said pre-finished interior surface comprises flooring.
 40. The modular building system according to claim 37, wherein said pre-finished interior surface comprises drywall.
 41. The modular building system according to claim 1, wherein said panel sections comprise means for routing electrical wiring.
 42. The modular building system according to claim 1, wherein said panel sections comprise means for routing plumbing.
 43. The modular building system according to claim 1, wherein said panel sections comprise means for routing communications cabling.
 44. The modular building system according to claim 1, wherein said panel sections comprise means for increasing the structural stability of said structural skeleton.
 45. The modular building system according to claim 44, wherein said means for increasing the structural stability of said structural skeleton comprises angle bracing within said panel sections.
 46. The modular building system according to claim 44, wherein said means for increasing the structural stability of said structural skeleton comprises cross bracing within said panel sections.
 47. The modular building system according to claim 44, wherein said means for increasing the structural stability of said structural skeleton comprises vertical bracing within said panel sections.
 48. The modular building system according to claim 44, wherein said means for increasing the structural stability of said structural skeleton comprises horizontal bracing within said panel sections.
 49. The modular building system according to claim 48, wherein said panel sections further comprise structural foam.
 50. The modular building system according to claim 1, wherein said panel sections comprise interior and exterior panels.
 51. The modular building system according to claim 50, wherein said interior and exterior panels have a pre-finished surface.
 52. The modular building system according to claim 50, wherein said panels have a flange to engage said tube section, said flange having a flange depth.
 53. The modular building system according to claim 52, wherein said tube sections are square, and each side of said square tube is twice the size of said flange depth.
 54. A structure, comprising: a selection of tube sections, a selection of removable connectors, wherein said connectors connect said tube sections together to form a structural skeleton comprising geometrically shaped sides, and a selection of geometrically shaped panel sections wherein said panel sections structurally engage said geometrically shaped sides of said structural skeleton.
 55. The structure according to claim 54, wherein said tube sections have a closed cross section.
 56. The structure according to claim 54, wherein said tube sections have an open cross section.
 57. The structure according to claim 54, wherein said tube sections comprise at least one channel to receive a flange on said connectors.
 58. The structure according to claim 54, wherein said tube sections comprise a channel to receive a flange on said panel sections.
 59. The structure according to claim 54, wherein said tube sections comprise a plurality of holes for receiving a fastener.
 60. The structure according to claim 54, wherein said removable connectors have a closed cross section.
 61. The structure according to claim 54, wherein said removable connectors have an open cross section.
 62. The structure according to claim 54, wherein said removable connectors comprise at least one flange for engaging a flange on said tube sections.
 63. The structure according to claim 54, wherein said removable connectors comprise a plurality of holes for receiving a fastener.
 64. The structure according to claim 54, wherein said panel sections comprise at least one flange for engaging said tube sections.
 65. The structure according to claim 54, wherein said panel sections comprise a plurality of holes for receiving a fastener.
 66. A method of constructing a structure, comprising the steps of: connecting a selection of tube sections with a selection of removable connectors, wherein said tube sections and said connectors form a structural skeleton having geometrically shaped sides, and connecting a selection of panel sections to said structural skeleton.
 67. The method according to claim 66, further comprising the step of removing said removable connectors after connecting said panel sections.
 68. The modular building system according to claim 24, wherein said panel sections comprise raised triangular perimeter sections having channels defined therebetween and recessed interiors, said channels and perimeter sections being adapted to engage said tube sections.
 69. The modular building system according to claim 68, wherein said tube sections are fastened to said panels via fasteners protruding through said perimeter sections into said tube sections.
 70. The modular building system according to claim 69, wherein said channels have a depth approximately half a depth of said tube sections, and wherein said system is configured such that an opposing panel section can be disposed in sandwiching relation with said panel section about said tube sections. 